Two-stage syngas production with separate char and product gas inputs into the second stage

ABSTRACT

A two-stage syngas production method to produce a final product gas from a carbonaceous material includes producing a first product gas in a first reactor, separating char from the first product gas to produce separated char and char-depleted product gas, and separately reacting the separated char and the char-depleted product gas with an oxygen-containing gas in a second reactor to produce a final product gas. The separated char is introduced into the second reactor above the char-depleted product gas. The solids separation device may include serially connected cyclones, and the separated char may be entrained in a motive fluid in an eductor to produce a char and motive fluid mixture prior to being transferred to the second reactor. A biorefinery method produces a purified product from the final product gas.

TECHNICAL FIELD

The present disclosure is directed to methods to produce product gas from carbonaceous materials using a two-step thermochemical process.

BACKGROUND

In recent years, there has been a shift towards innovative energy and environmental technologies to moderate climate change, reduce greenhouse gas emissions, reduce air and water pollution, promote economic development, expand energy supply options, increase energy security, decrease dependence on imported oil, and strengthen rural economies.

One of these technologies entails conversion of a carbonaceous material into a product gas which can then be converted into liquid fuels, chemicals, renewable natural gas, hydrogen, hydrocarbons and other useful products. A product gas generation system is described which includes a first reactor, a solids separation device, and a second reactor, and is configured to convert a carbonaceous material into product gas. Carbonaceous material along with one or more gaseous or liquid reactants may be introduced into a pressurized reactor, or steam reformer, where they undergo one or more thermochemical reactions to produce a product gas including char. Ideally, the carbonaceous material is introduced into the reactor such that: feedstock throughput is high, the feedstock has high surface area to promote thermochemical reactions, the feedstock is distributed within the reactor, and the pressure of the reactor is maintained, even as the carbonaceous material is continuously being introduced into the reactor.

Char may be separated from the product gas to produce a char-depleted product gas, and both the separated char and char-depleted product gas may be introduced into a second reactor, or a char/hydrocarbon reformer. Within the second reactor, char is oxidized into carbon dioxide, carbon monoxide, and other gases, and hydrocarbons present within the char-depleted product gas are converted into additional product gas including hydrogen and carbon monoxide. Within the second reactor, reacting the oxygen-containing gas with the separated char to produce a combustion stream, and reacting the combustion stream with the char-depleted product gas to produce a final product gas, the final product gas having a reduced amount of char and a reduced amount of hydrocarbons, relative to the char-depleted product gas. This simple two-step thermochemical process is new and has advantages in that is reduces capital intensity, reduces physical outlay of the gasifier island of the integrated biorefinery, increases carbon intensity, and provides for a simple, cost-effective installation.

An Integrated Biorefinery (IBR) is described and is configured to convert a carbonaceous material into a useful intermediate and/or purified product, wherein the IBR includes a feedstock preparation system, a feedstock delivery system, the product gas production system, a primary gas clean-up system, a compression system, a secondary gas clean-up system, a production system, and a purification or upgrading system. In embodiments, the IBR may include a two-stage gasifier island and may be configured to produce and purify or upgrade products from large quantities of carbonaceous materials including jet fuel, gasoline, diesel, alcohols such as ethanol, mixed alcohols, methanol, dimethyl ether, chemicals or chemical intermediates (plastics, solvents, adhesives, fatty acids, acetic acid, carbon black, olefins, oxochemicals, ammonia, etc.), Fischer-Tropsch products (LPG, Naphtha, Kerosene/diesel, lubricants, waxes), or synthetic natural gas.

In some instances, the product gas discharged from the second reactor, or the char/hydrocarbon reformer, may be converted into hydrogen, synthetic natural gas, or power. Processing of large quantities of carbonaceous materials requires having sufficient throughput in each of a number of serially connected systems. The capacities of the various systems should be selected so that they collectively cooperate to meet up-time and fuel production requirements while also maximizing the return on investment (ROI).

SUMMARY

This Summary is provided merely to introduce certain concepts and not to identify any key or essential features of the claimed subject matter.

-   Paragraph A. A method of producing a final product gas from a     carbonaceous material, comprising: -   in a first reactor, steam reforming the carbonaceous material to     produce a first product gas including char, hydrogen, carbon     monoxide, carbon dioxide, and hydrocarbons; -   in a solids separation device external to the first reactor,     separating the char from the first product gas to produce separated     char and char-depleted product gas, wherein the char-depleted     product gas has a reduced amount of char relative to the first     product gas; -   introducing into a second reactor, the separated char via a first     char input and the char-depleted product gas via a product gas input     distinct from the first char input; -   introducing an oxygen-containing gas into the second reactor; and -   in the second reactor, reacting the oxygen-containing gas with the     separated char and the char-depleted product gas to produce a final     product gas, the final product gas having a reduced amount of char     and a reduced amount of hydrocarbons, relative to the char-depleted     product gas;     -   wherein: -   along a vertical axis of the second reactor, the separated char is     introduced into the second reactor above the char-depleted product     gas. -   Paragraph B. The method according to Paragraph A, wherein the solids     separation device comprises serially connected first and second     cyclones; and the method comprises: -   passing the first product gas through both the first and second     cyclones to produce the char-depleted product gas, with the first     cyclone producing the separated char and the second cyclone     producing additional char; and -   introducing, into the second reactor, the separated char via the     first char input and the additional char via a second char input. -   Paragraph C. The method according to Paragraph B, comprising: -   introducing into the second reactor, both the separated char and the     additional char above the char-depleted product gas. -   Paragraph D. The method according to Paragraph A, wherein: -   the hydrocarbons in the first product gas include low molecular     weight hydrocarbons, aromatic hydrocarbons, and/or polyaromatic     hydrocarbons; and -   the low molecular weight hydrocarbons include one or more selected     from the group consisting of methane, ethane, ethylene, propane,     propylene, butane, and butene. -   Paragraph E. The method according to Paragraph A, comprising: -   introducing a fuel to the second reactor; and -   reacting the oxygen-containing gas with the fuel using a burner in     the second reactor. -   Paragraph F. The method according to Paragraph E, wherein: -   the fuel includes one or more selected from the group consisting of     tail-gas, Fischer-Tropsch tail-gas, natural gas, conditioned syngas,     propane, a methane-containing gas, naphtha, and off-gas from a     liquid fuel upgrading unit. -   Paragraph G. The method according to Paragraph A, comprising: -   entraining the separated char in a motive fluid to produce a char     and motive fluid mixture; and -   transferring the char and motive fluid mixture to the second     reactor; -   wherein: the motive fluid comprises one or more selected from the     group consisting of a gas, carbon dioxide, nitrogen, tail-gas,     conditioned syngas, syngas, off-gas from a downstream reactor,     steam, superheated steam, a vapor, and a superheated vapor. -   Paragraph H. The method according to Paragraph A, wherein: -   entraining the separated char in the motive fluid in an eductor to     produce the char and motive fluid mixture. -   Paragraph I. The method according to Paragraph A, comprising, in the     first reactor: -   indirectly heating particulate heat transfer material in the first     reactor with a plurality of pulse combustion heat exchangers; and -   introducing superheated steam and the carbonaceous material into the     first reactor to steam reform the carbonaceous material. -   Paragraph J. The method according to Paragraph I, comprising: -   also introducing an oxygen-containing gas into the first reactor to     promote partial oxidation of the carbonaceous material to produce     carbon monoxide and carbon dioxide. -   Paragraph K. The method according to Paragraph A, wherein: -   introducing additional oxygen-containing gas into the second reactor     between the first char input and the product gas input along the     vertical axis to promote partial oxidation of the char-depleted     product gas, wherein the additional oxygen-containing gas. -   Paragraph L. A method to produce a purified product from     carbonaceous material, comprising: -   producing a final product gas from the carbonaceous material     according to Paragraph A after introducing the carbonaceous material     into the first reactor from a feedstock delivery system; -   in a primary gas clean-up system, cooling and removing solids and     water vapor from the final product gas to produce a first cleaned     product gas; -   in a compression system, compressing the first cleaned product gas     to produce a compressed product gas; -   in a secondary gas clean-up system, removing contaminants and carbon     dioxide from the compressed product gas to produce a second cleaned     product gas and a carbon dioxide-rich stream; -   in a production system, producing an intermediate product from at     least a portion of the second cleaned product gas, the intermediate     product includes one or more selected from the group consisting of     liquid fuel, a chemical, ethanol, mixed alcohols, methanol, dimethyl     ether, Fischer-Tropsch products, and synthetic natural gas; and -   in a purification system, purifying or upgrading the intermediate     product to produce a purified product, wherein the purification     system includes one or more selected from the group consisting of     isomerization, hydrotreating, hydrocracking, distillation, and     adsorption. -   Paragraph M. The method according to Paragraph L, comprising: -   recycling and mixing at least a portion of the carbon dioxide-rich     stream removed in the secondary gas clean-up system with the char     produced in Paragraph A to produce a mixture of char and carbon     dioxide, and transferring the mixture of char and carbon dioxide to     the first char input of the second reactor. -   Paragraph N. The method according to Paragraph L, wherein: -   in the production system, producing tail gas, and recycling and     mixing at least a portion of the tail gas with the char produced in     Paragraph A to produce a mixture of char and gas, and transferring     the mixture of char and tail gas to the first char input of the     second reactor. -   Paragraph O. The method according to Paragraph L, wherein: -   in the production system, producing tail-gas, and introducing at     least a portion of the tail-gas to the second reactor, and reacting     the tail-gas with the oxygen-containing gas prior to reaction with     the char and/or the char-depleted product gas. -   Paragraph P. The method according to Paragraph L, wherein: -   in the purification system, producing an off-gas stream, and     recycling and mixing at least a portion of the off-gas stream with     the char produced in claim 1 to produce a mixture of char and gas,     and transferring the mixture of mixture of char and gas to the first     char input of the second reactor; and/or -   in the purification system, producing off-gas stream, and     introducing at least a portion of the off-gas stream to the second     reactor, and reacting the off-gas stream with the oxygen-containing     gas prior to reaction with the char and/or the char-depleted product     gas. -   Paragraph Q. The method according to Paragraph L, wherein: -   the first reactor comprises a cylindrical, up-flow,     refractory-lined, steel pressure vessel including a fluidized bed;     and -   the second reactor comprises a cylindrical, down-flow,     non-catalytic, refractory-lined, steel pressure vessel. -   Paragraph R. The method according to Paragraph L, wherein:     -   the carbonaceous material includes municipal solid waste; and     -   in a feedstock preparation system, processing the municipal         solid waste to produce sorted municipal solid waste in at least         one processing step, including one or more processing steps         selected from the group consisting of large objects removal,         recyclables removal, ferrous metal removal, size reduction,         drying or water removal, biowaste removal, non-ferrous metal         removal, polyvinyl chloride removal, glass removal, size         reduction and pathogen removal; and     -   introducing the sorted municipal solid waste to the feedstock         delivery system. -   Paragraph S. The method according to Paragraph L, wherein: -   in the production system, producing the intermediate product from at     least a portion of the second cleaned product gas within one or more     reactors selected from the group consisting of a multi-tubular     reactor, a multi-tubular fixed-bed reactor, an entrained flow     reactor, a slurry reactor, a fluid bed reactor, a circulating     catalyst reactor, a riser reactor, a can reactor, a microchannel     reactor, a fixed bed reactor, a bioreactor and a moving bed reactor. -   Paragraph T. The method according to Paragraph S, wherein: -   the reactor includes one or more bioreactors selected from the group     consisting of a continuous stirred tank bioreactor, a bubble column     bioreactor, a microbubble reactor, an airlift bioreactor, a     fluidized bed bioreactor, a packed bed bioreactor and a     photo-bioreactor. -   Paragraph U. The method according to Paragraph T, wherein: -   the bioreactor includes genetically modified organisms which undergo     anaerobic respiration. -   Paragraph V. A biorefinery system configured to produce a purified     product from carbonaceous material, the system includes:     -   a feedstock delivery system configured to accept and transfer a         source of carbonaceous material to a first reactor, wherein the         feedstock delivery system includes one or more systems selected         from the group consisting of a plug feeder system, a         densification system, a lock-hopper system, a screw auger, and a         solids transport conduit;     -   the first reactor configured to steam reform the carbonaceous         material to produce a first product gas including char,         hydrogen, carbon monoxide, carbon dioxide, and hydrocarbons;     -   a solids separation device configured to accept the first         product gas and separate the char therefrom to produce separated         char and char-depleted product gas, wherein the char-depleted         product gas has a reduced amount of char relative to the first         product gas;     -   a second reactor having a vertical axis and configured to accept         both the separated char via a first char input and the         char-depleted product gas via a product gas input, the first         char input being at a higher elevation along the vertical axis         than the product gas input, the second reactor configured to         react the oxygen-containing gas with the separated char and the         char-depleted product gas to produce a final product gas, the         final product gas having a reduced amount of char and a reduced         amount of hydrocarbons, relative to the char-depleted product         gas;     -   a primary gas clean-up system configured to cool and removing         solids and water vapor from the final product gas to produce a         first cleaned product gas;     -   a compression system configured to compress the first cleaned         product gas to produce a compressed product gas;     -   a secondary gas clean-up system configured to remove         contaminants and carbon dioxide from the compressed product gas         to produce a second cleaned product gas and a carbon         dioxide-rich stream;     -   a production system configured to produce an intermediate         product from at least a portion of the second cleaned product         gas, the intermediate product includes one or more selected from         the group consisting of liquid fuel, a chemical, ethanol, mixed         alcohols, methanol, dimethyl ether, Fischer-Tropsch products,         and synthetic natural gas; and     -   a purification system configured to purify the intermediate         product to produce a purified product, wherein the purification         system includes one or more selected from the group consisting         of isomerization, hydrotreating, hydrocracking, distillation,         and adsorption. -   Paragraph W. The biorefinery system according to Paragraph V,     wherein: -   the second reactor includes a burner configured to react the     oxygen-containing gas with a fuel. -   Paragraph X. The biorefinery system according to Paragraph V,     wherein: -   the first reactor comprises a cylindrical, up-flow,     refractory-lined, steel pressure vessel including a fluidized bed;     and -   the second reactor comprises a cylindrical, down-flow,     non-catalytic, refractory-lined, steel pressure vessel. -   Paragraph Y. The biorefinery system according to Paragraph V,     further comprising: -   an eductor configured to receive and entrain the separated char in a     motive fluid, prior to introducing the char into the second reactor. -   Paragraph Z. The biorefinery system according to Paragraph V,     wherein: -   the solids separation device comprises serially connected first and     second cyclones through which the first product gas passes to remove     char. -   Paragraph AA. The biorefinery system according to Paragraph V,     comprising: -   a feedstock preparation system configured to accept a source of     carbonaceous material comprising municipal solid waste and produce     sorted municipal solid waste in at least one processing step,     including one or more processing steps selected from the group     consisting of large objects removal, recyclables removal, ferrous     metal removal, size reduction, drying or water removal, biowaste     removal, non-ferrous metal removal, polyvinyl chloride removal,     glass removal, size reduction, and pathogen removal; and -   the feedstock delivery system is configured to accept the sorted     municipal solid waste from the feedstock preparation system as the     source of carbonaceous material. -   Paragraph AB. The biorefinery system according to Paragraph V,     wherein: -   the production system includes a reactor, the reactor includes one     or more reactors selected from the group consisting of a     multi-tubular reactor, a multi-tubular fixed-bed reactor, an     entrained flow reactor, a slurry reactor, a fluid bed reactor, a     circulating catalyst reactor, a riser reactor, a can reactor, a     microchannel reactor, a fixed bed reactor, a bioreactor, and a     moving bed reactor. -   Paragraph AC. The biorefinery system according to Paragraph V,     wherein: -   the production system comprises bioreactor including one or more     selected from the group consisting of a continuous stirred tank     bioreactor, a bubble column bioreactor, a microbubble reactor, an     airlift bioreactor, a fluidized bed bioreactor, a packed bed     bioreactor, and a photo-bioreactor. -   Paragraph AD. The biorefinery system according to Paragraph V,     wherein: -   the production system comprises bioreactor including one or more     selected from the group consisting of a continuous stirred tank     bioreactor, a bubble column bioreactor, a microbubble reactor, an     airlift bioreactor, a fluidized bed bioreactor, a packed bed     bioreactor, and a photo-bioreactor.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures show schematic process flowcharts of preferred embodiments and variations thereof. A full and enabling disclosure of the content of the accompanying claims, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures showing how the preferred embodiments and other non-limiting variations of other embodiments described herein may be carried out in practice, in which:

FIG. 1 shows a simplistic block flow diagram of one embodiment of a product gas production system (1000).

FIG. 2 shows a simplistic block flow diagram of one embodiment of a product gas production system (1000) including: a first reactor (100) configured to produce a first product gas (122) including char, a solids separation device (150) configured to separate the char from the first product gas (122) to produce separated char (144) and char-depleted product gas (126), and a second reactor (200) configured to separately accept both the separated char (144) and the char-depleted product gas (126), wherein the separated char (144) is introduced to the second reactor at a first elevation (EL1) and the char-depleted product gas (126) at a second elevation (EL2), wherein the first elevation is higher than the second elevation along a vertical axis (AX2) of the second reactor (200).

FIG. 2A shows a simplistic diagram of another embodiment of a product gas production system (1000) including: a first reactor (100) configured to produce a first product gas (122) including char, a first solids separation device (150) configured to separate the char from the first product gas (122) to produce separated char (144) and a first char-depleted product gas (126), a second solids separation device (150′) configured to separate additional char from the first char-depleted product gas (126) to produce additional separated char (144′) and a second char-depleted product gas (126′), and a second reactor (200) configured to separately accept both streams of separated char (144, 144′) and the second char-depleted product gas (126′), wherein both streams of separated char (144, 144′) are introduced to the second reactor (200) at two first elevations (ELL ELF) and the second char-depleted product gas (126′) is also introduced at a second elevation (EL2), wherein both of the first elevations (ELL ELF) are located higher than the second elevation (EL2) along a vertical axis (AX2) of the second reactor (200).

FIG. 3 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (3-1), a first annular port (3-2), a second annular port (3-3), and a third annular port (3-4).

FIG. 4 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (4-1), a first annular port (4-2), and a second annular port (4-3).

FIG. 5 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (5-1), a first annular port (5-2), and a second annular port (5-3).

FIG. 6 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (6-1) and a first annular port (6-2).

FIG. 7 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes a pulse combustor.

FIG. 8 shows another simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes a pulse combustor.

FIG. 9 shows a simplistic diagram of one embodiment of Integrated Biorefinery (IBR) including the product gas production system (1000) as disclosed in FIGS. 1, 2 and 2A.

DETAILED DESCRIPTION Notation and Nomenclature

Before the disclosed systems and processes are described, it is to be understood that the aspects described herein are not limited to specific embodiments, apparatus, or configurations, and as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and, unless specifically defined herein, is not intended to be limiting.

As used herein the term “carbonaceous material” refers to a solid or liquid substance that contains carbon such as for instance, agricultural residues, agro-industrial residues, animal waste, biomass, cardboard, coal, coke, energy crops, farm slurries, fishery waste, food waste, fruit processing waste, lignite, municipal solid waste (MSW), paper, paper mill residues, paper mill sludge, paper mill spent liquors, plastics, refuse derived fuel (RDF), sewage sludge, tires, urban waste, wood products, wood wastes and a variety of others. All carbonaceous materials contain both “fixed carbon components” and “volatile components”, such as for example woody biomass, MSW, or RDF.

As used herein the term “char” refers to a carbon-containing solid residue derived from a carbonaceous material and is comprised of the “fixed carbon components” of a carbonaceous material. Char includes carbon and ash.

As used herein the term “product gas” refers to syngas or flue gas discharged from a thermochemical reactor undergoing thermochemical processes including pyrolysis, steam reforming, partial oxidation, dry reforming, or combustion.

As used herein the term “syngas” refers to a mixture of carbon monoxide (CO), hydrogen (H₂), and other vapors/gases, also including char, if any and usually produced when a carbonaceous material reacts with steam (H₂O), carbon dioxide (CO₂) and/or oxygen (O₂). While steam is the reactant in steam reforming, CO₂ is the reactant in dry reforming. Generally, for operation at a specified temperature, the kinetics of steam reforming is faster than that of dry reforming and so steam reforming tends to be favored and more prevalent. Syngas might also include low molecular weight hydrocarbons (like methane, ethane, ethylene, propane, propylene, butane, butene, etc.), aromatic hydrocarbons such as volatile organic compounds (VOC) and/or semi-volatile organic compounds (SVOC).

As used herein the term “volatile organic compounds” or acronym “(VOC)” or “VOC” refer to aromatic hydrocarbons including benzene, toluene, phenol, styrene, xylene, and cresol.

As used herein the term “semi-volatile organic compounds” or acronym “(SVOC)” or “SVOC” refer to polyaromatic hydrocarbons, such as indene, indane, naphthalene, methylnaphthalene, acenaphthylene, acenaphthalene, anthracene, phenanthrene, (methyl-) anthracenes/phenanthrenes, pyrene/fluoranthene, methylpyrenes/benzofluorenes, chrysene, benz[a]anthracene, methylchrysenes, methylbenz[a]anthracenes, perylene, benzo[a]pyrene, dibenz[a,kl]anthracene, and dibenz[a,h]anthracene.

As used herein the term “oxygen-containing gas” refers to air, oxygen-enriched-air i.e. greater than 21 mole % O₂, or substantially pure oxygen, i.e. greater than about 95 mole % oxygen (the remainder usually comprising N₂ and/or rare gases). In embodiments, an air separation unit (ASU) is used to produce a source of “oxygen-containing gas” from air. In embodiments, a plurality of air separation unit (ASU) are used to produce a source of “oxygen-containing gas” from air.

In embodiments, the air separation unit (ASU) includes a fractional distillation unit. In embodiments, the air separation unit (ASU) includes a plurality of fractional distillation units. In embodiments, the air separation unit (ASU) includes a cryogenic air separation unit. In embodiments, the air separation unit (ASU) includes a plurality of cryogenic air separation units. In embodiments, the air separation unit (ASU) includes a membrane or a plurality of membranes. In embodiments, the air separation unit (ASU) includes a pressure swing adsorption (PSA) unit. In embodiments, the air separation unit (ASU) includes a plurality of pressure swing adsorption (PSA) units. In embodiments, the air separation unit (ASU) includes a vacuum pressure swing adsorption (VPSA) unit. In embodiments, the air separation unit (ASU) includes a plurality of vacuum pressure swing adsorption (VPSA) units. In embodiments, the air separation unit (ASU) includes one or more selected from the group consisting of a fractional distillation unit, cryogenic air separation unit, a membrane, a pressure swing adsorption (PSA) unit, a vacuum pressure swing adsorption (VPSA) unit. In embodiments, the air separation unit (ASU) includes two or more selected from the group consisting of a fractional distillation unit, cryogenic air separation unit, a membrane, a pressure swing adsorption (PSA) unit, a vacuum pressure swing adsorption (VPSA) unit.

As used herein the term “flue gas” refers to a vapor or gaseous mixture containing varying amounts of nitrogen (N₂), carbon dioxide (CO₂), water (H₂O), and oxygen (O₂). Flue gas is generated from the thermochemical process of combustion.

As used herein the term “thermochemical process” refers to a broad classification including various processes that can convert a carbonaceous material into product gas. Among the numerous thermochemical processes or systems that can be considered for the conversion of a carbonaceous material, the present disclosure contemplates: pyrolysis, steam reforming, partial oxidation, dry reforming, and/or combustion. Thermochemical processes may be either endothermic or exothermic in nature depending upon the specific set of processing conditions employed. Stoichiometry and composition of the reactants, type of reactants, reactor temperature and pressure, heating rate of the carbonaceous material, residence time, carbonaceous material properties, and catalyst or bed additives all dictate what sub classification of thermochemical processing the system exhibits.

As used herein the term “thermochemical reactor” refers to a reactor (e.g., a first reactor, a second reactor) that accepts a carbonaceous material, char, low molecular weight hydrocarbons, VOC, SVOC, or product gas and converts it into one or more product gases.

Pyrolysis Reaction:

As used herein the term “pyrolysis” is the endothermic thermal degradation reaction that organic material goes through in its conversion into a more reactive liquid/vapor/gas state.

Carbonaceous material+heat→VOC+SVOC+H₂O+CO+CO₂+H₂+CH₄+low molecular weight hydrocarbons+char

Steam Reforming Reactions:

As used herein the term “steam reforming” refers to a thermochemical process where steam reacts with a carbonaceous material to yield syngas. The main reaction is endothermic (consumes heat) wherein the operating temperature range is between 570° C. and 900° C. (1,058° F. and 1,652° F.), depending upon the chemistry of the carbonaceous material.

H₂O+C+Heat→H₂+CO

Water Gas Shift Reaction:

As used herein the term “water-gas shift” refers to a thermochemical process comprising a specific chemical reaction that occurs simultaneously with the steam reforming reaction to yield hydrogen and carbon dioxide. The main reaction is exothermic (releases heat) wherein the operating temperature range is between 570° C. and 900° C. (1,058° F. and 1,652° F.), depending upon the chemistry of the carbonaceous material.

H₂O+CO→H₂+CO₂+Heat

Dry Reforming Reaction:

As used herein the term “dry reforming” refers to a thermochemical process comprising a specific chemical reaction where carbon dioxide is used to convert a carbonaceous material into carbon monoxide. The reaction is endothermic (consumes heat) wherein the operating temperature range is between 600° C. and 1,000° C. (1,112° F. and 1,832° F.), depending upon the chemistry of the carbonaceous material.

CO₂+C+Heat→2CO

Partial Oxidation Reaction:

As used herein the term “partial oxidation” refers to a thermochemical process wherein sub-stoichiometric oxidation of a carbonaceous material takes place to exothermically produce carbon monoxide, carbon dioxide and/or water vapor. The reactions are exothermic (release heat) wherein the operating temperature range is between 500° C. and 1,700° C. (932° F. and 3,092° F.), depending upon the chemistry of the carbonaceous material. Oxygen reacts exothermically (releases heat): 1) with the carbonaceous material to produce carbon monoxide and carbon dioxide; 2) with hydrogen to produce water vapor; and 3) with carbon monoxide to produce carbon dioxide.

4C+3O₂→CO+CO₂+Heat

C+½O₂→CO+Heat

H₂+½O₂→H₂O+Heat

CO+½O₂→CO₂+Heat

Combustion Reaction:

As used herein the term “combustion” refers to an exothermic (releases heat) thermochemical process wherein at least the stoichiometric oxidation of a carbonaceous material takes place to generate flue gas.

C+O₂→CO₂+Heat

CH₄+O₂→CO₂+2H₂O+Heat

Some of these reactions are fast and tend to approach chemical equilibrium while others are slow and remain far from reaching equilibrium. The composition of the product gas will depend upon both quantitative and qualitative factors. Some are unit specific i.e. reactor size/scale specific and others are carbonaceous material feedstock specific. The quantitative parameters are: carbonaceous material properties, carbonaceous material injection flux, reactor operating temperature, pressure, gas and solids residence times, carbonaceous material heating rate, fluidization medium and fluidization flux; the qualitative factors are: degree of bed mixing and gas/solid contact, and uniformity of fluidization and carbonaceous material injection.

Reference will now be made in detail to various embodiments of the disclosure. Each embodiment is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the disclosure without departing from the teaching and scope thereof. For instance, features illustrated or described as part of one embodiment to yield a still further embodiment derived from the teaching of the disclosure. Thus, it is intended that the disclosure or content of the claims cover such derivative modifications and variations to come within the scope of the disclosure or claimed embodiments described herein and their equivalents.

Additional objects and advantages of the disclosure will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the claims. The objects and advantages of the disclosure will be attained by means of the instrumentalities and combinations and variations particularly pointed out in the appended claims.

FIG. 1:

FIG. 1 shows a simplistic diagram of one embodiment of a product gas production system (1000). The product gas production system (1000) of FIG. 1 includes a first reactor (100), a solids separation device (150), and a second reactor (200).

In embodiments, the first reactor (100) includes a first interior (101) and has a first vertical axis (AX1). In embodiments, the second reactor (200) includes a second interior (201) and has a second vertical axis (AX2). The first reactor (100) generates a first product gas (122) by reacting a source of carbonaceous material (102) with a reactant (106), such as superheated steam, in a steam reforming reaction, wherein the first product gas (122) includes syngas comprising hydrogen, carbon monoxide, carbon dioxide, low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds, and char. In embodiments, the second reactor includes a char/hydrocarbon reformer.

A particulate heat transfer material (105) is contained within the interior (101) of the first reactor (100) and is configured to provide contact with the carbonaceous material (102) and a reactant (106), such as steam, superheated steam, and optionally carbon dioxide (recycled from downstream secondary gas clean-up section of the Integrated Biorefinery (IBR) as shown in FIG. 9). In embodiments, the product gas production system (1000) is included inside of an Integrated Biorefinery (IBR).

In embodiments, the particulate heat transfer material (105) is comprised of alumina, zirconia, sand, olivine sand, limestone, dolomite, or catalytic materials, any of which may be hollow in form, such as microballoons or microspheres. In embodiments, a first oxygen-containing gas (118) is provided to the interior (101) of the first reactor (100) to react with the carbonaceous material (102). In embodiments, a source of carbon dioxide is provided to the first reactor (100) together with the source of carbonaceous material (102), wherein the carbonaceous material (102) includes a mixture of carbonaceous material and carbon dioxide. In embodiments, the particulate heat transfer material (105) enhances mixing, heat and mass transfer, and reaction between the carbonaceous material (102), reactant (106), and the first oxygen-containing gas (118) within the interior (101) for the first reactor (100).

The first product gas (122) is discharged from the first reactor (100) via a first product gas output (124) and is routed towards a solids separation device (150) which separates the char (144) from the first product gas (122) to produce separated char (144) and char-depleted product gas (126). The char-depleted product gas (126) has a reduced amount of char (144) within it relative to the first product gas (122).

The solids separation device (150) accepts the first product gas (122) via a first separation input (152). The solids separation device (150) accepts the first product gas (122) from the first product gas output (124) of the first reactor (100). The solids separation device (150) includes any conceivable means to separate solid char from the first product gas, and preferably includes a cyclone, a filter, or a separator. The char-depleted product gas (126) is discharged from the solids separation device (150) via the first separation gas output (156). The separated char (144) is discharged from the solids separation device (150) via the first separation char output (154).

The second reactor (200) is configured to accept both the separated char (144) and the char-depleted product gas (126) discharged from the solids separation device (150). The separated char (144) is introduced to the interior (201) of the second reactor (200) via a first char input (204). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via a product gas input (206).

In embodiments, the first char input (204) is positioned at a first elevation (EL1) along the second vertical axis (AX2) of the second reactor (200). In embodiments, the product gas input (206) is positioned at a second elevation (EL2) along the second vertical axis (AX2) of the second reactor (200). In embodiments, the first char input (204) at the first elevation (EL1) is higher than the second elevation (EL2) of the product gas input (206). In embodiments, the separated char (144) is introduced to the interior (201) of the second reactor (200) at an elevation higher than where the product gas input (206) is introduced to the interior (201) of the second reactor (200).

The separated char (144) and the char-depleted product gas (126) are both reacted within the interior (201) of the second reactor (200) to produce a second reactor product gas (222). The second reactor product gas (222) is discharged from the second reactor (200) via a second product gas output (224). In embodiments, the second reactor product gas (222) is a final product gas resulting from this new two-step thermochemical process. The separated char (144) is reacted with a second oxygen-containing gas (218) within the interior (201) of the second reactor (200) to produce carbon monoxide and/or carbon dioxide. The char-depleted product gas (126) is reacted with a second oxygen-containing gas (218) and the products of the char reaction within the interior (201) of the second reactor (200) to produce additional product gas, or additional syngas, not only including hydrogen, carbon monoxide, and carbon dioxide. The char-depleted product gas (126) is reacted with a second oxygen-containing gas (218) within the interior (201) of the second reactor (200) to produce an improved syngas having a higher concentration of carbon monoxide and hydrogen, relative to that found in the char-depleted product gas (126).

FIG. 2:

FIG. 2 shows a simplistic diagram of one embodiment of a product gas production system (1000) including: a first reactor (100) configured to produce a first product gas (122) including char, a solids separation device (150) configured to separate the char from the first product gas (122) to produce separated char (144) and char-depleted product gas (126), and second reactor (200) configured to separately accept both the separated char (144) and the char-depleted product gas (126), wherein the separated char (144) is introduced to the second reactor at a first elevation (EL1) and the char-depleted product gas (126) at a second elevation (EL2), wherein the first elevation is higher than the second elevation along a vertical axis (AX2) of the second reactor (200).

The product gas production system (1000) of FIG. 2 includes a more detailed view of the first reactor (100), a solids separation device (150), and a second reactor (200) as depicted in FIG. 1. In embodiments, the first reactor (100) includes a first interior (101) and has a first vertical axis (AX1). In embodiments, the second reactor (200) includes a second interior (201) and has a second vertical axis (AX2).

FIG. 2 shows a carbonaceous material (102) being introduced to the interior (101) of the first reactor (100) via an input (104). In the first reactor (100) the source of carbonaceous material (102) is steam reformed, via a steam reforming reaction, to produce the first product gas (122) including syngas comprising hydrogen, carbon monoxide, carbon dioxide, low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds, and char.

A particulate heat transfer material (105) is contained within the interior (101) first reactor (100) and is configured to provide contact with the carbonaceous material (102) and a reactant (106), such as steam, superheated steam, and optionally carbon dioxide (recycled from downstream secondary gas clean-up section of the Integrated Biorefinery (IBR) as shown in FIG. 9).

A first reactor heat exchanger (HX-1) is immersed beneath a fluid bed level (L-1) of the particulate heat transfer material (105). The first reactor heat exchanger (HX-1) may include a plurality of heat exchangers, such as pulse combustion heat exchangers. Any type of heat exchanger may be used, such as pulse heater tailpipes, electrical heater rods in thermowells, fuel cells, heat pipes, fire-tubes, annulus-type heat exchangers, or radiant tubes.

In embodiments, the first reactor heat exchanger (HX-1) may be a pulse combustion heat exchanger that combusts a source of fuel (110) to form a pulse combustion stream (114) comprising flue gas. The pulse combustion stream (114) indirectly heats the particulate heat transfer material (105) of the first reactor (100). As used herein, indirectly heating the particulate heat transfer material (105) means that the pulse combustion stream (114) does not contact the contents of the particulate heat transfer material (105) within the first reactor (100). In other words, the pulse combustion stream (114) indirectly heats the particulate heat transfer material (105) which in turn directly contacts the carbonaceous material (102), reactant (106), and the first oxygen-containing gas (118) within the interior (101) of the first reactor (100). In embodiments, the fuel for the plurality of pulse combustion heat exchangers includes one or more selected from the group consisting of conditioned syngas, tail-gas, Fischer Tropsch tail-gas, naphtha, off-gases from a downstream liquid fuel production system, natural gas, steam-diluted natural gas, propane, hydrocarbons, and hydrocarbon mixtures.

In embodiments, the particulate heat transfer material (105) is comprised of alumina, zirconia, sand, olivine sand, limestone, dolomite, or catalytic materials, any of which may be hollow in form, such as microballoons or microspheres. In embodiments, the particulate heat transfer material (105) enhances mixing, heat and mass transfer, and reaction between the carbonaceous material (102), reactant (106), and the first oxygen-containing gas (118). In embodiments, the first reactor includes a steam reformer. In embodiments, the first reactor includes an indirectly heated steam reformer.

In embodiments, a first oxygen-containing gas (118) is provided to the interior (101) of the first reactor (100) via a first oxygen-containing gas input (120) to react with the carbonaceous material (102). In embodiments, a reactant (106), such as steam, or superheated steam, a vapor, or a superheated vapor, is provided to the interior (101) of the first reactor (100) via a reactant input (108) to react with the carbonaceous material (102). In embodiments, the first oxygen-containing gas input (120) and the reactant input (108) are not separate inputs to the first reactor (100), and are introduced to the first reactor (100) as a mixture of the reactant (106) and the first oxygen-containing gas (118), and are introduced to the interior (101) of the first reactor (100) through a fluidization distributor (121) to fluidize particulate heat transfer (105) included therein, as shown in FIG. 2. In embodiments, the first oxygen-containing gas input (120) and the reactant input (108) are separate inputs to the first reactor (100).

FIG. 2 shows a first reactor (100) having a first interior (101) provided with a freeboard zone (FB-1) located above the fluid bed level (L-1) of the particulate heat transfer material (105). In embodiments, an internal cyclone (125) is positioned within the freeboard zone (FB-1) of the first reactor (100). The internal cyclone (125) is configured to separate particulate heat transfer material (105) from, product gas within the freeboard zone (FB-1) of the first reactor (100) and return the particulate heat transfer material (105) back to below the fluid bed level (L-1) while permitting the product gas to leave the interior (101) of the first reactor (100) en route to the solids separation device (150).

The first product gas (122) is discharged from the first reactor (100) via a first product gas output (124) and is routed towards a solids separation device (150) which separates the char (144) from the first product gas (122) to produce separated char (144) and a char-depleted product gas (126), wherein the char-depleted product gas (126) has a reduced amount of char (144) within it relative to the first product gas (122).

The solids separation device (150) accepts the first product gas (122) via a first separation input (152). The solids separation device (150) accepts the first product gas (122) from the first product gas output (124) of the first reactor (100). The solids separation device (150) includes any conceivable means to separate solid char from the first product gas, and preferably includes a cyclone, a filter, or a separator. The char-depleted product gas (126) is discharged from the solids separation device (150) via the first separation gas output (156). The separated char (144) is discharged from the solids separation device (150) via the first separation char output (154).

In embodiments, a source of motive fluid (149), such as carbon dioxide, a gas such as conditioned syngas or tail-gas or off-gas from a downstream reactor, steam, superheated steam, a vapor, a superheated vapor, is mixed with the separated char (144) for transporting the separated char (144) to the first char input (204) of the second reactor (200). In embodiments, the motive fluid with mixed with or entrains the separated char to produce a char and motive fluid mixture, and then transferring the char and motive fluid mixture to the second reactor for reaction with an oxygen-containing gas, wherein: the motive fluid comprises one or more selected from the group consisting of a gas, carbon dioxide, nitrogen, tail-gas, conditioned syngas, syngas, off-gas from a downstream reactor, steam, superheated steam, a vapor, and a superheated vapor.

In embodiments, an eductor (148) is used to mix and transport the motive fluid (149) with the separated char (144) to be transferred to the first char input (204) of the second reactor (200). In embodiments, the eductor (148) may include a venturi eductor and/or a venturi transport system for dilute phase pneumatic conveying of the char (144) into the second reactor (200) with the motive fluid (148). In embodiments, the eductor (148) includes a Solids Handling Eductor provided by Schutte & Koerting located at 2510 Metropolitan Drive, Trevose, Pa. 19053 (www.s-k.com).

The second reactor (200) is configured to accept both the separated char (144) and the char-depleted product gas (126) discharged from the solids separation device (150). The separated char (144) is introduced to the interior (201) of the second reactor (200) via a first char input (204). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via a product gas input (206). The solids separation device (150) separates the char from the first product gas (122) to provide two separate streams, the separated char (144) and the char-depleted product gas (126), which are then separately introduced to the interior (201) of the second reactor (201) at two different reaction zones. The kinetics of reacting the separated char (144) into additional product gas are much slower than reacting char-depleted product gas (126) into additional product gas. This difference in reaction kinetics is the main reason for first introducing the separated char (144) into a higher region of the second reactor (200) followed by secondly introducing the char-depleted product gas (126) into a relatively lower region of the second reactor (200).

In embodiments, the first char input (204) is positioned at a first elevation (EL1) along the second vertical axis (AX2) of the second reactor (200). In embodiments, the product gas input (206) is positioned at a second elevation (EL2) along the second vertical axis (AX2) of the second reactor (200). In embodiments, the first char input (204) at the first elevation (EL1) is higher than the second elevation (EL2) of the product gas input (206). In embodiments, the first char input (204) is higher than the product gas input (206) along the second vertical axis (AX2) of the second reactor (200). In embodiments, the separated char (144) is introduced to the interior (201) of the second reactor (200) at an elevation higher than where the product gas input (206) is introduced to the interior (201) of the second reactor (200). The separated char (144) and the char-depleted product gas (126) are both reacted within the interior (201) of the second reactor (200) to produce a second reactor product gas (222).

In embodiments, a second reactor heat exchanger (HX-2) is in thermal contact with the interior (201) of the second reactor (200). In embodiments, the second reactor heat exchanger (HX-2) may include a radiant syngas cooler. In embodiments, the second reactor heat exchanger (HX-2) may include radiant syngas cooler with a double shell design or a membrane wall. In embodiments, the second reactor heat exchanger (HX-2) is configured to remove heat from within the interior (201) of the second reactor (200) by use of a heat transfer medium (210). In embodiments, the heat transfer medium (210) enters the second reactor heat exchanger (HX-2) via a heat transfer medium inlet (212) and exits via a heat transfer medium outlet (216). The heat transfer medium (210) leaving the second reactor heat exchanger (HX-2) via the heat transfer medium outlet (216) is at a higher temperature than the heat transfer medium (210) entering the second reactor heat exchanger (HX-2) via the heat transfer medium inlet (212).

The second reactor product gas (222) is discharged from the interior (201) of the second reactor (200) via a second product gas output (224). In embodiments, solids (338), such as ash, molten ash, slag are discharged from the interior (201) of the second reactor (200) via a solids output (340).

In embodiments, the first reactor (100) may be a cylindrical, up-flow, catalytic, refractory-lined, steel pressure vessel with a fluidized bed. In embodiments, the first reactor (100) may be a cylindrical, up-flow, non-catalytic, refractory-lined, steel pressure vessel with a fluidized bed. In embodiments, the second reactor (200) may be a cylindrical, down-flow, non-catalytic, refractory-lined, steel pressure vessel. In embodiments, the second reactor (200) may be rectangular.

In embodiments, a sufficient amount of oxygen-containing gas (218) is provided to a burner (246) of the second reactor (200) so that excess oxygen-containing gas (218) remains unreacted and exits the burner (246) and thus is also available to react the separated char (144) and/or the char-depleted product gas (126). In embodiments, the separated char (144) may either be the primary or secondary fuel that reacts with the oxygen-containing gas (118). Herein, the oxygen-containing gas (218) may be staged and the flow streams swirled as necessary to manage the mixing, stoichiometry, flame length, and temperature.

Oxidation or combustion, or partial oxidation, of a source of fuel (240) occurs within the burner (246) where the fuel (240) is reacted with the oxygen-containing gas (218) to generate a combustion stream (250). In embodiments, the oxygen-containing gas (218) is introduced to the burner (246) in superstoichiometric amounts in proportion and relative to the fuel (240) so as to substantially, completely combust the fuel (240) to generate carbon dioxide and heat along with an unreacted amount of oxygen-containing gas (218). In embodiments, a superstoichiometric amount of oxygen is provided to the burner (246) so that when all of the fuel (240) is burned, there is still excess oxygen-containing gas (218) left over. In embodiments, the combustion stream (250) exits the burner (246) in substoichiometric amounts in proportion and relative to the char (144) and/or the char-depleted product gas so as to substantially, completely react the char and/or the low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds present within the char-depleted product gas to produce carbon monoxide.

In embodiments, the fuel (240) may be tail-gas from a downstream reactor, Fischer Tropsch tail-gas, natural gas, propane, a methane-containing gas, naphtha, conditioned syngas, product gas, off-gas from a downstream reactor, or even landfill gas including a complex mix of different gases created by the action of microorganisms within a landfill. The char-depleted product gas (126) is reacted with the combustion stream (250) exiting the burner (246) to produce additional carbon monoxide and hydrogen.

In embodiments, the burner (246) is an annulus type burner employed to react the fuel (240) with the oxygen-containing gas (218) through the thermochemical process of combustion. In embodiments, the burner (246) is a multi-orifice, co-annular, burner provided with an arrangement of several passages coaxial with the longitudinal axis of the burner. Multi-orifice burners comprising arrangements of annular concentric channels for reacting the oxygen-containing gas (218) with the fuel (240) may, in some instances, have a reduced area to permit a high velocity stream to take place and result in very rapid and complete reaction of the combustion stream (250) with the separated char (144) and/or the char-depleted product gas (126) to produce additional carbon monoxide. The design of the burner (246) is not particularly relevant in FIG. 2. Various types of burners may be used as disclosed in FIGS. 3 to 8. Preferably, a burner (246) is selected that is configured to react either a combustible fuel (240) or separated char (144) or a mixture thereof with an oxygen-containing gas (218) via combustion reaction to produce an intensely hot combustion stream (250) comprising carbon dioxide, oxygen, and heat. The burner may be equipped with an ignitor.

FIG. 2 shows the burner (246) is that of an annulus type. In embodiments, the burner (246) may be of the type configured to accept the fuel (240) and the oxygen-containing gas (218) through concentric ports, wherein the oxygen-containing gas (218) is injected into an annular port (245), and the fuel (240) is injected to the central port (247). The burner (246) ensures rapid and intimate mixing and combustion of the fuel (240) with the oxygen-containing gas (218). The fuel (240) and the oxygen-containing gas (218) are introduced under pressure and combustion of the fuel (240) is completed in the burner (246) and terminates at the burner nozzle (255). In embodiments, the burner (246) is constructed such that the reaction between the fuel (240) and the oxygen-containing gas (218) takes place entirely outside the burner (246) and only at the burner nozzle (247) so as to provide protection of the burner (246) from overheating and from direct oxidation. In embodiments, the burner (246) or the burner nozzle (247) is equipped with a cooling water circuit (260) which circulates a source of cooling water (261) within a portion of the burner (246).

In embodiments, the burner nozzle (247) may be defined by a restriction constituting a reduction in area to provide an increase in velocity of the combustion stream (250) exiting the burner nozzle (247). The restriction may even be in some instances a baffle or an impingement plate on which the flame of the combustion stream is stabilized. The burner nozzle (247) may have a restricting or constricting throat zone, or orifice to accelerate velocity of the combustion stream (250) in the transition from the combustion zone to the interior (201) of the second reactor (200) where reaction of the combustion stream (250) and the separated char (144) and/or the char-depleted product gas (126) takes place. A restriction, orifice, baffle, or impingement surface is advantageous to shield the combustion occurring within the burner (246) from pressure fluctuations within the interior (201) of the second reactor (200) to mediate operational difficulties such as burner oscillation, flash-back, detonation, and blow-out.

In embodiments, combustion stream (250) exiting the burner nozzle (247) may be transferred at velocities within the range of 200 feet per minute (ft/m) to the speed of sound under the existing conditions. But advantageously the combustion stream (250) that is discharged from the burner (246), via the burner nozzle (247), is at a velocity between 50 and 500 feet per second (ft/s) and typically less than 300 ft/s.

The separated char (144) and/or the char-depleted product gas (126) introduced to the interior (201) of the second reactor (200) which come into contact with the combustion stream (250) must not be allowed to remain at high temperatures for more than a fraction of a second, or more than a few seconds, the critical reaction period limits being about 0.1 second to about 10 seconds. Normally it is advantageous to maintain reaction time between the separated char (144) and/or the char-depleted product gas (126) and the combustion stream (250) of 1 to 6 seconds to sufficiently completely react the low molecular weight hydrocarbons, SVOC, VOC, and char into additional hydrogen and carbon monoxide and products of combustion. Preferably the residence time of the separated char (144) and/or the char-depleted product gas (126) and the combustion stream (250) in the reaction zone is about 4 seconds.

The combustion stream (250) discharged from burner (246) is comprised of an intensely hot mixture of carbon dioxide and excess oxygen-containing gas. The heat generated between the combustion of the fuel (240) with the oxygen-containing gas (218) in turn elevates the temperature of the excess unreacted oxygen-containing gas (218) contained within the combustion stream (250) to a temperature up to 1,500° C. (2,732° F.). It is preferred to operate the burner (246) at about 1,300° C. (2,372° F.). In embodiments, the combustion stream (250) exiting the burner (246) operates at a temperature ranging from about 1,000° C. (1,832° F.) to 1,700° C. (3,092° F.). In embodiments, a nozzle (255) comprising a baffle or impingement plate might be installed to shield the burner (246) from the interior (201) of the second reactor (200).

In embodiments, the burner (246) is a Helmholtz pulse combustion resonator (as disclosed in FIGS. 7 and 8). An oxygen-containing gas (218) and a hydrocarbon (240) may be introduced into the burner (246) to produce the combustion stream (250) via a pulse combustion reaction. Thus, the burner (246) may comprise an aerodynamic valve or fluidic diode, combustion chamber and tailpipe or tailpipes. This pulse burner (246) will typically operate in a cyclic fashion comprising the steps of fuel and oxygen-containing gas intake or recharge, compression, ignition and expansion. An ignition or spark source detonates the explosive mixture during start-up. The pulsating flow generated in this burner is characterized by a pressure anti-node in the combustion chamber and a velocity anti-node at the exit of the tailpipe. This results in combustion chamber pressure varying from a low (below mean) to a high (above mean) and this aids in drawing in fuel and oxygen-containing gas during recharge and in pushing out the combustion products through the tailpipe(s) during expansion. The flow exiting the tailpipe is characterized by a high velocity pulsating flow which facilitates good mixing of the exiting oxygen-rich products and the separated char (144) and/or char-depleted product gas (126). Once the first cycle is initiated, operation is thereafter self-sustaining or self-aspirating.

A pulse combustor burner (246) used herein, and as noted above, is based on a Helmholtz configuration with an aerodynamic valve. The pressure fluctuations, which are combustion-induced in the Helmholtz resonator-shaped combustion burner (246), coupled with the fluidic diodicity of the aerodynamic valve burner (246) and nozzle (247), cause a biased flow of the combustion stream (250) from the burner (246), through the nozzle (247) and into the interior (201) of the second reactor (200). This results in the oxygen-containing gas (218) being self-aspirated by the burner (246) and for an average pressure boost to develop in the burner (246) to expel the products of combustion at a high average flow velocity (typically over 300 ft/s) into and through the nozzle (247).

The production of an intense acoustic wave is an inherent characteristic of pulse combustion. Sound intensity in the combustion chamber of burner (246) is normally in the range of 150-190 dB. The operating frequency may range from 40 to 250 Hz and more typically between 50 and 150 Hz.

FIG. 2 shows one non-limiting representation of a burner (246) including a central port (247) and an annular port (245), wherein a second oxygen-containing gas (218) is introduced to the central port (247), and a fuel (240) is introduced to the annular port (245). In embodiments, the fuel (240) introduced to the burner (246) may be tail-gas from a downstream reactor, Fischer Tropsch tail-gas, natural gas, propane, a methane-containing gas, naphtha, conditioned syngas, product gas, off-gas from a downstream reactor, or even landfill gas including a complex mix of different gases created by the action of microorganisms within a landfill. FIGS. 3 to 8 show other non-limiting representations of the burner (246) which is integrated with the second reactor (200).

FIG. 2A:

FIG. 2A shows a simplistic diagram of another embodiment of a product gas production system (1000) including: a first reactor (100) configured to produce a first product gas (122) including char, a first solids separation device (150) configured to separate the char from the first product gas (122) to produce separated char (144) and a first char-depleted product gas (126), a second solids separation device (150′) configured to separate additional char from the first char-depleted product gas (126) to produce additional separated char (144′) and a second char-depleted product gas (126′), and a second reactor (200) configured to separately accept both streams of separated char (144, 144′) and the second char-depleted product gas (126′), wherein both streams of separated char (144, 144′) are introduced to the second reactor (200) at two first elevations (EL1, ELF) and the second char-depleted product gas (126′) is also introduced at a second elevation (EL2), wherein both of the first elevations (EL1, ELF) are located higher than the second elevation (EL2) along a vertical axis (AX2) of the second reactor (200).

In embodiments, the solids separation device may comprise a plurality of serially connected elements, each configured to separate char from product gas. FIG. 2A shows an embodiment (embodiment 2) in which serially connected cyclones (150, 150′) are each shown to remove char (144, 144′). The char (144,144′) is then introduced into the second reactor (200) via distinct first and second char inputs (204, 204′), the first char input (204) being at a first char elevation (EL1) which is higher than a second char elevation (EL2) of the second char input (204′). However, both char inputs (204, 204′) are at a higher elevation than the product gas input (206). While the embodiment seen in FIG. 2A shows a solid separation device comprising two cyclones), it is understood that more than two cyclones (or other elements) may be serially connected.

In the embodiment of FIG. 2A a first product gas (122) is discharged from the first reactor (100) via the first product gas output (124). The first product gas (122) is introduced to the first solids separation device (150) to produce a first char-depleted product gas (126) and the separated char (144). The first char-depleted product gas (126) is then introduced to the second solids separation device (150′) to produce a second char-depleted product gas (126′) and additional separated char (144′). The separated char (144) is routed from the char output (154) of the first solids separation device (150) to a first char input (204) of the second reactor (100) at a first elevation (EL1). The additional separated char (144′) is routed from the char output (154′) of the second solids separation device (150′) to a second char input (204′) of the second reactor (100) at another first elevation (EL1′).

Char (144) is separated from the first product gas (122) in the first solids separation device (150) and is mixed with motive fluid (149) and transported to the first char input (204) of the second reactor (100). The circle with the “X” in the center illustrates a continuous stream transferring the char (144) and the motive fluid (149) to the first char input (204) of the second reactor (100). The additional char (144′) is separated from the char-depleted product gas (126) in the second solids separation device (150′) and is mixed with a motive fluid (149′) and transported to the second char input (204′) of the second reactor (100). FIGS. 2 and 2A both show the motive fluid (149, 149′) transferred from FIG. 9 as recycled carbon dioxide, however, a gas, nitrogen, tail-gas from a downstream reactor, conditioned syngas, syngas, off-gas from a downstream reactor, steam, superheated steam, a vapor, and a superheated vapor may also be used.

In embodiments, an eductor (148) is used to mix and transport the motive fluid (149) with the separated char (144) to be transferred to the char input (204) of the second reactor (200). In embodiments, the eductor (148) may include a venturi eductor and/or a venturi transport system for dilute phase pneumatic conveying of the char (144) into the second reactor (200) with the motive fluid (148). In embodiments, the eductor (148) includes a Solids Handling Eductors provided by Schutte & Koerting located at 2510 Metropolitan Drive, Trevose, Pa. 19053 (www.s-k.com). In embodiments, a first eductor (148) is used to mix and transport the motive fluid (149) with the separated char (144) to be transferred to the first char input (204) of the second reactor (200). In embodiments, a second eductor (148′) s used to mix and transport the motive fluid (149′) with the additional separated char (144′) to be transferred to the second char input (204′) of the second reactor (200).

FIG. 3:

FIG. 3 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (3-1), a first annular port (3-2), a second annular port (3-3), and a third annular port (3-4). In embodiments, the first annular port is closest to the central port (3-1); and the second annular port (3-3) is positioned in between the first annular port (3-2) and the third annular port (3-4).

Fuel (240) is introduced to the central port (3-1), an oxygen containing gas (218) is introduced to the first annular port (3-2), the separated char (144) is introduced to the second annular port (3-3) (via the char input (204) located at a first elevation (EL1)), additional oxygen containing gas (218-2) is introduced to the third annular port (3-4). The separated char (144) introduced to the burner (246) of the second reactor (200) is introduced at a first elevation (EL1), via the char input (204), located along the vertical axis (AX2) of the second reactor (200). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) at a second elevation (EL2), via a product gas input (206), located along the vertical axis (AX2) of the second reactor (200), wherein the second elevation (EL2) is located below the first elevation (EL1).

FIG. 4:

FIG. 4 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (4-1), a first annular port (4-2), and a second annular port (4-3). FIG. 4 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (4-1), a first annular port (4-2), and a second annular port (4-3); wherein the first annular port is closest to the central port (4-1).

The separated char (144) is introduced to the central port (4-1), an oxygen containing gas (218) is introduced to the first annular port (4-2), and additional oxygen containing gas (218-2) is introduced to the second annular port (4-3). The separated char (144) introduced to the burner (246) of the second reactor (200) is introduced via the char input (204), at a first elevation (EL1) located along the vertical axis (AX2) of the second reactor (200). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via the product gas input (206) located at a second elevation (EL2) located along the vertical axis (AX2) of the second reactor (200), wherein the second elevation (EL2) is located below the first elevation (EL1).

FIG. 5:

FIG. 5 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (5-1), a first annular port (5-2), and a second annular port (5-3). FIG. 5 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (5-1), a first annular port (5-2), and a second annular port (5-3); wherein the first annular port is closest to the central port (5-1). Fuel (240) is introduced to the central port (5-1), an oxygen containing gas (218) is introduced to the first annular port (5-2), the separated char (144) is introduced to the second annular port (5-3).

The separated char (144) introduced to the burner (246) of the second reactor (200) is introduced via the char input (204) at a first elevation (EL1) located along the vertical axis (AX2) of the second reactor (200). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via the product gas input (206) at a second elevation (EL2) located along the vertical axis (AX2) of the second reactor (200), wherein the second elevation (EL2) is located below the first elevation (EL1). In embodiments, an additional oxygen-containing gas (218-2) may either be introduced coaxially to the char-depleted product gas (126) or separately at a third elevation (EL3) in between the first elevation (EL1) and the second elevation (EL2). In embodiments, the additional oxygen-containing gas (218-2) is introduced into the second reactor (200) to promote partial oxidation of the char-depleted product gas.

FIG. 6:

FIG. 6 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes: a central port (6-1) and a first annular port (6-2). The separated char (144) is introduced to the central port (6-1) and an oxygen containing gas (218) is introduced to the first annular port (6-2).

The separated char (144) introduced to the burner (246) of the second reactor (200) is introduced via the char input (204) at a first elevation (EL1) located along the vertical axis (AX2) of the second reactor (200). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) at a second elevation (EL2) located along the vertical axis (AX2) of the second reactor (200), via the product gas input (206) wherein the second elevation (EL2) is located below the first elevation (EL1).

In embodiments, an additional oxygen-containing gas (218-2) may either be introduced coaxially to the char-depleted product gas (126) or separately at a third elevation (EL3) in between the first elevation (EL1) and the second elevation (EL2). In embodiments, the additional oxygen-containing gas (218-2) is introduced into the second reactor (200) to promote partial oxidation of the char-depleted product gas.

FIG. 7:

FIG. 7 shows a simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes a pulse combustor. FIG. 7 shows the burner (246) as a pulse combustor. The pulse combustion burner (246) includes: an inlet section (290), a combustion section (292), and a resonance section (294). FIG. 7 shows the inlet section (290) configured to accept both an oxygen-containing gas (218) and a fuel (240). The oxygen-containing gas (218) and a fuel (240) are mixed and then combusted in the combustion section (292) to produce a combustion stream (250).

The separated char (144) is introduced to the interior (201) of the second reactor (200) via a char input (204) located at a first elevation (EL1) located along the vertical axis (AX2) of the second reactor (200). The separated char (144) introduced at the first elevation (EL1) first reacts with the combustion stream (250) which contains oxygen to substantially convert the separated char (144) into carbon monoxide and carbon dioxide.

The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via the product gas input (206) located at the second elevation (EL2), lower than the first elevation (EL2), then reacts with the products of the separated char (144) and combustion stream (250) to substantially convert the low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds within the char-depleted product gas (126) into carbon monoxide and hydrogen. In embodiments, an additional oxygen-containing gas (218-2) may either be introduced coaxially to the char-depleted product gas (126) or separately at a third elevation (EL3) in between the first elevation (EL1) and the second elevation (EL2) to achieve and maintain the desired operating temperature and conversion. In embodiments, the additional oxygen-containing gas (218-2) is introduced into the second reactor (200) to promote partial oxidation of the char-depleted product gas.

FIG. 8:

FIG. 8 shows another simplistic representation of a burner (246) connected to the second reactor (200), wherein the burner (246) includes a pulse combustor. FIG. 8 shows the burner (246) as a pulse combustor. The pulse combustion burner (246) includes: an inlet section (290), a combustion section (292), and a resonance section (294). FIG. 8 shows the inlet section (290) configured to accept both an oxygen-containing gas (218) and separated char (144), wherein the separated char (144) is introduced to the burner (246) at a first elevation (EL1) located along the vertical axis (AX2) of the second reactor (200). The oxygen-containing gas (218) and the separated char (144) are mixed and then combusted in the combustion section (292) to produce a combustion stream (250).

The separated char (144) introduced via the char input (204) located at the first elevation (EL1) first reacts with the oxygen-containing gas (218) to form the combustion stream (250). The char-depleted product gas (126) introduced via the product gas input (206) located at the second elevation (EL2), lower than the first elevation (EL2), then reacts with the combustion stream (250) to substantially convert the low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds within the char-depleted product gas (126) into carbon monoxide and hydrogen. In embodiments, an additional oxygen-containing gas (218-2) may either be introduced coaxially to the char-depleted product gas (126) or separately at a third elevation (EL3) in between the first elevation (EL1) and the second elevation (EL2) to achieve and maintain the desired operating temperature and conversion.

FIG. 9:

FIG. 9 shows a simplistic diagram of one embodiment of Integrated Biorefinery (IBR) including the product gas production system (1000) as disclosed in FIGS. 1, 2, and 2A. In embodiments, the product gas production system (1000) as disclosed in FIGS. 1, 2, and 2A is included within an Integrated Biorefinery (IBR) for the conversion of a carbonaceous material (102) into a useful product (1500).

In embodiments, the Integrated Biorefinery (IBR) includes a feedstock preparation system (25), a feedstock delivery system (50), the product gas generation system (1000), a primary gas clean-up system (300), a compression system (400), a secondary gas clean-up system (500), a production system (600), and a purification system (700).

In embodiments, the feedstock preparation system (25) is configured to accept a carbonaceous material via an input (25-1) and discharge a carbonaceous material via an output (25-2). In embodiments, the feedstock preparation system (25) processes the carbonaceous material in at least one processing step, including one or more processing steps selected from the group consisting of large objects removal, recyclables removal, ferrous metal removal, size reduction, drying or water removal, biowaste removal, non-ferrous metal removal, polyvinyl chloride removal, glass removal, size reduction, and pathogen removal.

In embodiments, the feedstock delivery system (50) is configured to accept, via an input (50-1), a carbonaceous material from the output (25-2) of the feedstock preparation system (25) and transfer the carbonaceous material to the input (104) of the first reactor (100) within the product gas production system (1000). In embodiments, the feedstock delivery system (50) is configured to transfer the carbonaceous material to interior of the pressurized first reactor and to form a seal between a pressurized interior (101) of the first reactor (100) and the input (50-1) of the feedstock delivery system (50). In embodiments, the feedstock delivery system (50) includes a plug feeder system configured to create plugs from the carbonaceous material, wherein the plugs are used to form a seal between a pressurized interior (101) of the first reactor (100). In embodiments, the feedstock delivery system (50) includes a densification system configured to create densify the carbonaceous material and form densified carbonaceous material, wherein the densified carbonaceous material is used to form a seal between a pressurized interior (101) of the first reactor (100). In embodiments, the feedstock delivery system (50) includes a screw auger configured to transport the carbonaceous material to the interior (101) of the first reactor (100). In embodiments, the feedstock delivery system (50) includes a solids transport conduit configured to transport solid carbonaceous material to the interior (101) of the first reactor (100). In embodiments, the feedstock delivery system (50) includes a lock-hopper configured to transport the carbonaceous material to the interior (101) of the first reactor (100). The carbonaceous material is discharged from the output (50-2) of the feedstock delivery system (50) and into the interior (101) of the first reactor (100) via an input (104).

In embodiments, the feedstock delivery system (50) is also configured to accept a recycle gas (104-0), such as carbon dioxide, discharged from a recycled gas output (500-3) of a downstream secondary gas clean-up system (500). In embodiments, the recycle gas (104-0) includes carbon dioxide and is removed from product gas in a downstream secondary gas clean-up system (500).

As disclosed in FIG. 9 (and in FIGS. 1 and 2), the product gas production system (1000) includes a first reactor (100), a solids separation device (150), and a second reactor (200). The first reactor (100) generates a first product gas (122) by reacting a source of carbonaceous material (102) with a reactant (106), such as superheated steam, in a steam reforming reaction, wherein the first product gas (122) includes syngas comprising hydrogen, carbon monoxide, carbon dioxide, low molecular weight hydrocarbons, volatile organic compounds, semi-volatile organic compounds, and char. The first product gas (122) is discharged from the first reactor (100) via a first product gas output (124) and is routed towards a solids separation device (150) which separates the char (144) from the first product gas (122) to produce separated char (144) and char-depleted product gas (126). The char-depleted product gas (126) has a reduced amount of char (144) within it relative to the first product gas (122).

In embodiments, the first reactor (100) is also configured to accept a recycle gas (104-1), such as carbon dioxide, discharged from a recycled gas output (500-3) of a downstream secondary gas clean-up system (500). In embodiments, the recycle gas (104-1) may be used for instrumentation purges for level and/or density measurement devices.

The solids separation device (150) accepts the first product gas (122) via a first separation input (152). The solids separation device (150) accepts the first product gas (122) from the first product gas output (124) of the first reactor (100). The char-depleted product gas (126) is discharged from the solids separation device (150) via the first separation gas output (156). The separated char (144) is discharged from the solids separation device (150) via the first separation char output (154).

The second reactor (200) is configured to accept both the separated char (144) and the char-depleted product gas (126) discharged from the solids separation device (150). The separated char (144) is introduced to the interior (201) of the second reactor (200) via a char input (204). The char-depleted product gas (126) is introduced to the interior (201) of the second reactor (200) via a product gas input (206).

In embodiments, the second reactor (200) is also configured to accept a recycle gas (104-2), such as carbon dioxide, discharged from a recycled gas output (500-3) of a downstream secondary gas clean-up system (500). In embodiments, the recycle gas (104-2) may be used for instrumentation purges for level and/or density measurement devices, and also may be used to a motive fluid (149) which can be mixed with the separated char (144) for transporting the separated char (144) to the char input (204) of the second reactor (200) (as seen in FIGS. 2 and 2A).

The separated char (144) and the char-depleted product gas (126) are both reacted within the interior (201) of the second reactor (200) to produce a second reactor product gas (222). The second reactor product gas (222) is discharged from the second reactor (200) via a second product gas output (224).

In embodiments, the primary gas clean-up system (300) is configured to accept, via an input (300-1), the second reactor product gas (222) discharged from the second reactor (200) via a second product gas output (224). In embodiments, the primary gas clean-up system (300) is configured cool and remove solids and water vapor from the second reactor product gas (222) and produce a first cleaned product gas which is discharged via an output (300-2).

In embodiments, the compression system (400) is configured to accept, via an input (400-1), the first cleaned product gas via the output (300-2) of the primary gas clean-up system (300) and compress the first cleaned product gas to produce a compressed product gas. The compressed product gas is discharged from an output (400-2) of the compression system (400) and is routed to the input (500-1) of the secondary gas clean-up system (500). The compression system (400) is configured to increase a pressure of the first cleaned product and discharge the compressed product gas via the output (400-2) at a second pressure greater than a first pressure at which the first cleaned product gas entered via the compression system input (400-1).

In embodiments, the secondary gas clean-up system (500) is configured to accept the compressed product gas from the output (400-2) of the compression system (400) and produce a second cleaned product gas that is discharged from an output (500-2) of the secondary gas clean-up system (500). In embodiments, the secondary gas clean-up system (500) is configured to remove carbon dioxide from at least a portion of the compressed product gas discharged from the compression system (400) with a carbon dioxide removal system to produce from a recycled gas output (500-3) which may then be used as a recycle gas, or a carbon dioxide-rich stream, in the feedstock delivery system (50) (as recycle gas (104-0)), the first reactor (100) (as recycle gas (104-1)), or to be mixed with the separated char (144) transferred to the second reactor (200) (as the recycle gas (104-2) which may be used as the motive fluid (149) for transferring the separated char (144) from the solids separation device (150) to the char input (204) of the second reactor (200) as seen in FIGS. 2 and 2A).

In embodiments, the secondary gas clean-up system (500) removes carbon dioxide from the compressed product gas using a carbon dioxide removal system. In embodiments, the carbon dioxide removal system within the secondary gas clean-up system (500) includes one or more systems selected from the group consisting of a membrane, solvent-based scrubbing systems using amines or physical solvents (i.e., Rectisol, Selexol, Sulfinol), a wet limestone scrubbing system, a spray dry scrubber, a clause processing system, a solvent based sulfur removal processes such as the UC Sulfur Recovery Process (UCSRP), a high temperature sorbent, glycol ether, diethylene glycol methyl ether (DGM), a regenerable sorbent, a non-regenerable sorbent, molecular sieve zeolites, calcium based sorbents, FeO, MgO or ZnO-based sorbents or catalysts, iron sponge, potassium-hydroxide-impregnated activated-carbon systems, impregnated activated alumina, titanium dioxide catalysts, vanadium pentoxide catalysts, tungsten trioxide catalysts, sulfur bacteria (Thiobacilli), sodium biphospahte solutions, aqueous ferric iron chelate solutions, potassium carbonate solutions, alkali earth metal chlorides, magnesium chloride, barium chloride, crystallization systems, bio-catalyzed scrubbing processes such as the THIOPAQ Scrubber, and hydrodesulphurization catalysts.

In embodiments, the secondary gas clean-up system (500) is also configured to remove contaminants from product gas, wherein the contaminants include ammonia (which can be removed via absorption and/or adsorption), VOCs (which can be removed via adsorption), sulfur (which can be removed via absorption and/or adsorption), carbonyl sulfide (which can be removed via hydrolysis), metals (which can be removed via absorption and/or adsorption), hydrogen purification (purified with adsorption and/or a membrane).

In embodiments, the production system (600) is configured to accept, via an input (600-1), and produce an intermediate product from at least a portion of the second cleaned product gas discharged from the output (500-2) of the secondary gas clean-up system (500). In embodiments, the production system (600) produces and discharges an intermediate product via an output (600-2) which is routed to the input (700-1) of a purification system (700). In embodiments, the production system (600) also produces and discharges a gaseous composition, or a tail-gas, via a recycle output (600-3) which is routed to the first reactor heat exchanger (HX-1) (as seen in FIGS. 2 and 2A), or to the burner (246) as shown in FIGS. 2 to 9 for use as the source of fuel (240). In embodiments, the production system (600) produces and discharges a gaseous composition, or the tail-gas, via a recycle output (600-3) which may be used as the motive fluid (149) and mixed with the separated char (144) to be transferred to the char input (204) of the second reactor (200).

In embodiments, the intermediate product produced in the production system (600) includes one or more systems selected from the group consisting of ethanol, mixed alcohols, methanol, dimethyl ether, chemicals or chemical intermediates (plastics, solvents, adhesives, fatty acids, acetic acid, carbon black, olefins, oxochemicals, ammonia, etc.), Fischer-Tropsch products (LPG, Naphtha, Kerosene/diesel, lubricants, waxes), synthetic natural gas. In embodiments, the production system (600) includes one or more production systems selected from the group consisting of a reactor, a methanation reactor, a multi tubular reactor, a multi tubular fixed-bed reactor, an entrained flow reactor, a slurry reactor, a fluid-bed reactor, a circulating catalyst reactor, a riser reactor, a can reactor, a microchannel reactor, a fixed bed reactor, a bioreactor, and a moving bed reactor.

In embodiments, the production system (600) includes a cobalt catalyst and/or an iron catalyst. In embodiments, the production system (600) includes a methanation reactor to produce synthetic natural gas from the second cleaned product gas. In embodiments, the production system (600) includes a catalyst and can produce liquid fuels such as mixed alcohols (e.g., a mixture of both ethanol and methanol), dimethyl ether, Fischer-Tropsch products, or the like. In embodiments, the production system (600) includes a bioreactor containing microorganisms. The microorganisms produce a liquid fuel (e.g., ethanol, 1-butanol, 2-butanol) and/or chemicals within the bioreactor.

In embodiments, the intermediate product includes a liquid fuel and/or a chemical that is produced in a bioreactor is then distilled in the purification system (700). In embodiments, the liquid fuel and/or a chemical produced in the bioreactor is then removed using a membrane. In embodiments, the liquid fuel and/or a chemical produced in the bioreactor is then dehydrated using pressure swing adsorption. In embodiments, the liquid fuel and/or a chemical produced in the bioreactor is then dehydrated using an adsorbent. In embodiments, the liquid fuel and/or a chemical produced in the bioreactor is then dehydrated using 3 angstrom molecular sieves.

In embodiments, the intermediate product includes a chemical produced in the bioreactor includes one or more selected from the group consisting of: 3-hydroxypropionate; mevalonate; mevalonic acid; isoprene; aromatics; benzoate (p-hydroxyl, 2-amino, dihydroxy); salicylate; 1-propanol; 1,2-propanediol; (R)-1,2-propanediol; (S)-1,2-propanediol; mixed isomers of 1,2-propanediol; acetoin; methyl ethyl ketone; branched-chain amino acids; valine, leucine, isoleucine; succinate; lactate; 2,3-butanediol; (R,R)-2,3-butanediol; meso-2,3-butanediol; mixed isomers of 2,3-butanediol; citramalate; 1,3-butanediol; (R)-1,3-butanediol; (S)-1,3-butanediol; mixed isomers of 1,3-butanediol; 3-hydroxybutyrate; (R)-3-hydroxybutyrate; (S)-3-hydroxybutyrate; mixed isomers of 3-hydroxybutyrate; butyrate; acetone; isopropanol; acetate; 1,3-butadiene; biopolymers; isobutene; long chain alcohols.

In embodiments, when ethanol is produced in the bioreactor of the production system (600), it is then distilled in the purification system (700). In embodiments, the ethanol produced in the bioreactor is then removed using a membrane. In embodiments, the ethanol produced in the bioreactor is then dehydrated using pressure swing adsorption. In embodiments, the ethanol produced in the bioreactor is then dehydrated using an adsorbent. In embodiments, the ethanol produced in the bioreactor is then dehydrated using 3 angstrom molecular sieves.

In embodiments, the bioreactor includes one or more type of bioreactors selected from the group consisting of a continuous stirred tank bioreactor, a bubble column bioreactor, a microbubble reactor, an airlift bioreactor, a fluidized bed bioreactor, a packed bed bioreactor, and a photo-bioreactor. In embodiments, the microorganisms used within the bioreactor include genetically modified organisms. In embodiments, the microorganisms used within the bioreactor do not include genetically modified organisms. In embodiments, the microorganisms used within the bioreactor include gas fermenting organisms. In embodiments, the microorganisms used within the bioreactor undergo anaerobic respiration. In embodiments, the microorganisms used within the bioreactor undergo fermentation. In embodiments, the microorganisms used within the bioreactor include anaerobic bacteria. In embodiments, the bioreactor includes a liquid nutrient medium used for culturing the microorganisms and the ethanol is produced within the bioreactor by the microorganisms which secrete ethanol which accumulates within the liquid nutrient medium.

In embodiments, the purification system (700) is configured to accept the intermediate product produced and discharged from the production system (600) via the output (600-2). A purified product (1500) is discharged from an output (700-2) of the purification system (700). In embodiments, the purification system (700) produces and discharges a gaseous composition, or off-gas stream, via a recycle output (700-3) which is routed to the first reactor heat exchanger (HX-1) (as seen in FIGS. 2 and 2A), or to the burner (246) as shown in FIGS. 2 to 9 for use as the source of fuel (240). In embodiments, the purification system (700) upgrades the intermediate product. In embodiments, the purification system (700) produces and discharges a gaseous composition, or the off-gas stream, via a recycle output (700-3) which may be used as the motive fluid (149) and mixed with the separated char (144) to be transferred to the char input (204) of the second reactor (200). In embodiments, if isomerization, hydrotreating, hydrocracking, distillation, and adsorption are used, the off-gas includes hydrogen or hydrocarbons. In embodiments, if synthetic natural gas is produced and adsorption is used the off-gas includes hydrogen or hydrocarbons.

In embodiments, the purification system (700) hydrotreats the intermediate product produced and discharged from the production system (600). In embodiments, the purification system (700) hydrocracks the intermediate product produced and discharged from the production system (600). In embodiments, the purification system (700) distills the intermediate product produced and discharged from the production system (600). In embodiments, the purification system (700) adsorbs impurities from the intermediate product produced and discharged from the production system (600). In embodiments, the purification system (700) accepts the intermediate product from the output (600-2) of the production system (600) and purifies with one or more processing steps selected from the group consisting of isomerization, hydrotreating, hydrocracking, distillation, and adsorption.

It will be appreciated that the foregoing examples, given for purposes of illustration, are not to be construed as limiting the scope of this disclosure. Although only a few exemplary embodiments of this disclosure have been described in detail above, those skilled in the art will readily appreciate that many variation of the theme are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this disclosure. Accordingly, all such modifications are intended to be included within the scope of this disclosure that is defined in the following claims and all equivalents thereto. Further, it is recognized that many embodiments may be conceived in the design of a given system that do not achieve all of the advantages of some embodiments, yet the absence of a particular advantage shall not be construed to necessarily mean that such an embodiment is outside the scope of the present disclosure.

Thus, specific systems and methods of a two-stage syngas production system integrated within an Integrated Biorefinery (IBR) have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Although the foregoing text sets forth a detailed description of numerous different embodiments of the disclosure, it should be understood that the scope of the disclosure is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment of the disclosure because describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the disclosure.

Thus, many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the spirit and scope of the present disclosure. Accordingly, it should be understood that the methods and apparatus described herein are illustrative only and are not limiting upon the scope of the disclosure.

Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the disclosure.

Groupings of alternative elements or embodiments of the disclosure disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.

It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

LISTING OR REFERENCE NUMERALS

-   product gas production system (1000) -   first reactor (100) -   interior (101) -   first vertical axis (AX1) -   carbonaceous material (102) -   input (104) -   particulate heat transfer material (105) -   reactant (106) -   reactant input (108) -   first fuel (110) -   combustion stream (114) -   first oxygen-containing gas (118) -   first oxygen-containing gas input (120) -   first product gas (122) -   first product gas output (124) -   internal cyclone (125) -   char-depleted product gas (126, 126′) -   char depleted product gas conduit (128, 128′) -   separated char (144, 144′) -   eductor (148, 148′) -   gas (149, 149′) -   solids separation device (150, 150′) -   first separation input (152, 152′) -   first separation char output (154, 154′) -   first separation gas output (156, 156′) -   fluid bed level (L-1) -   fluidization distributor (121) -   freeboard (FB-1) -   first reactor heat exchanger (HX-1) -   first elevation (EL1) -   second elevation (EL2) -   second reactor (200) -   interior (201) -   second vertical axis (AX2) -   char input (204, 204′) -   product gas input (206) -   oxygen-containing gas (218) -   second oxygen-containing gas input (220) -   second product gas output (224) -   second reactor product gas (222) -   fuel (322) -   burner (346) -   central port (347) -   annular port (345) -   burner nozzle (355) -   second reactor heat exchanger (HX-2) -   heat transfer medium outlet (216) -   heat transfer medium inlet (212) -   heat transfer medium (210) -   solids (338) -   solids output (340) -   combustion stream (350) -   inlet section (405) -   combustion section (410) -   tail pipe section (415) -   third elevation (EL3) -   feedstock preparation system (25) -   input (25-1) -   output (25-2) -   feedstock delivery system (50) -   input (50-1) -   output (50-2) -   recycle gas (104-0) -   recycle gas (104-1) -   recycle gas (104-2) -   primary gas clean-up system (300) -   input (300-1) -   output (300-2) -   compression system (400) -   input (400-1) -   output (400-2) -   secondary gas clean-up system (500) -   input (500-1) -   output (500-2) -   recycled gas output (500-3) -   production system (600) -   input (600-1) -   output (600-2) -   recycle-gas (600-3) -   purification system (700) -   input (700-1) -   output (700-2) -   recycle-gas (700-3) 

What is claimed is:
 1. A method of producing a final product gas from a carbonaceous material, comprising: in a first reactor, steam reforming the carbonaceous material to produce a first product gas including char, hydrogen, carbon monoxide, carbon dioxide, and hydrocarbons; in a solids separation device external to the first reactor, separating the char from the first product gas to produce separated char and char-depleted product gas, wherein the char-depleted product gas has a reduced amount of char relative to the first product gas; introducing into a second reactor, the separated char via a first char input and the char-depleted product gas via a product gas input distinct from the first char input; introducing an oxygen-containing gas into the second reactor; and in the second reactor, reacting the oxygen-containing gas with the separated char and the char-depleted product gas to produce a final product gas, the final product gas having a reduced amount of char and a reduced amount of hydrocarbons, relative to the char-depleted product gas; wherein: along a vertical axis of the second reactor, the separated char is introduced into the second reactor above the char-depleted product gas.
 2. The method according to claim 1, wherein the solids separation device comprises serially connected first and second cyclones; and the method comprises: passing the first product gas through both the first and second cyclones to produce the char-depleted product gas, with the first cyclone producing the separated char and the second cyclone producing additional char; and introducing, into the second reactor, the separated char via the first char input and the additional char via a second char input.
 3. The method according to claim 2, comprising: introducing into the second reactor, both the separated char and the additional char above the char-depleted product gas, along the vertical axis.
 4. The method according to claim 1, wherein: the hydrocarbons in the first product gas include low molecular weight hydrocarbons, aromatic hydrocarbons, and/or polyaromatic hydrocarbons; and the low molecular weight hydrocarbons include one or more selected from the group consisting of methane, ethane, ethylene, propane, propylene, butane, and butene.
 5. The method according to claim 1, comprising: introducing a fuel to the second reactor; and reacting the oxygen-containing gas with the fuel using a burner in the second reactor.
 6. The method according to claim 5, wherein: the fuel includes one or more selected from the group consisting of tail-gas, Fischer-Tropsch tail-gas, natural gas, conditioned syngas, propane, a methane-containing gas, naphtha, and off-gas from a liquid fuel upgrading unit.
 7. The method according to claim 1, comprising: entraining the separated char in a motive fluid to produce a char and motive fluid mixture; and transferring the char and motive fluid mixture to the second reactor; wherein: the motive fluid comprises one or more selected from the group consisting of a gas, carbon dioxide, nitrogen, tail-gas, conditioned syngas, syngas, off-gas from a downstream reactor, steam, superheated steam, a vapor, and a superheated vapor.
 8. The method according to claim 7, comprising: entraining the separated char in the motive fluid in an eductor to produce the char and motive fluid mixture.
 9. The method according to claim 1, comprising, in the first reactor: indirectly heating particulate heat transfer material in the first reactor with a plurality of pulse combustion heat exchangers; and introducing superheated steam and the carbonaceous material into the first reactor to steam reform the carbonaceous material.
 10. The method according to claim 9, comprising: also introducing an oxygen-containing gas into the first reactor to promote partial oxidation of the carbonaceous material to produce carbon monoxide and carbon dioxide.
 11. The method according to claim 1, wherein: introducing additional oxygen-containing gas into the second reactor between the first char input and the product gas input along the vertical axis to promote partial oxidation of the char-depleted product gas.
 12. A method to produce a purified product from carbonaceous material, comprising: producing a final product gas from the carbonaceous material according to claim 1 after introducing the carbonaceous material into the first reactor from a feedstock delivery system; in a primary gas clean-up system, cooling and removing solids and water vapor from the final product gas to produce a first cleaned product gas; in a compression system, compressing the first cleaned product gas to produce a compressed product gas; in a secondary gas clean-up system, removing contaminants and carbon dioxide from the compressed product gas to produce a second cleaned product gas and a carbon dioxide-rich stream; in a production system, producing an intermediate product from at least a portion of the second cleaned product gas, the intermediate product includes one or more selected from the group consisting of liquid fuel, a chemical, ethanol, mixed alcohols, methanol, dimethyl ether, Fischer-Tropsch products, and synthetic natural gas; and in a purification system, purifying or upgrading the intermediate product to produce a purified product, wherein the purification system includes one or more selected from the group consisting of isomerization, hydrotreating, hydrocracking, distillation, and adsorption.
 13. The method according to claim 12, comprising: recycling and mixing at least a portion of the carbon dioxide-rich stream removed in the secondary gas clean-up system with the char produced in claim 1 to produce a mixture of char and carbon dioxide, and transferring the mixture of char and carbon dioxide to the first char input of the second reactor.
 14. The method according to claim 12, wherein: in the production system, producing tail gas, and recycling and mixing at least a portion of the tail gas with the char produced in claim 1 to produce a mixture of char and gas, and transferring the mixture of char and tail gas to the first char input of the second reactor.
 15. The method according to claim 12, wherein: in the production system, producing tail-gas, and introducing at least a portion of the tail-gas to the second reactor, and reacting the tail-gas with the oxygen-containing gas prior to reaction with the char and/or the char-depleted product gas.
 16. The method according to claim 12, wherein: in the purification system, producing an off-gas stream, and recycling and mixing at least a portion of the off-gas stream with the char produced in claim 1 to produce a mixture of char and gas, and transferring the mixture of mixture of char and gas to the first char input of the second reactor; and/or in the purification system, producing off-gas stream, and introducing at least a portion of the off-gas stream to the second reactor, and reacting the off-gas stream with the oxygen-containing gas prior to reaction with the char and/or the char-depleted product gas.
 17. The method according to claim 12, wherein: the first reactor comprises a cylindrical, up-flow, refractory-lined, steel pressure vessel including a fluidized bed; and the second reactor comprises a cylindrical, down-flow, non-catalytic, refractory-lined, steel pressure vessel.
 18. The method according to claim 12, wherein: the carbonaceous material includes municipal solid waste; and in a feedstock preparation system, processing the municipal solid waste to produce sorted municipal solid waste in at least one processing step, including one or more processing steps selected from the group consisting of large objects removal, recyclables removal, ferrous metal removal, size reduction, drying or water removal, biowaste removal, non-ferrous metal removal, polyvinyl chloride removal, glass removal, size reduction and pathogen removal; and introducing the sorted municipal solid waste to the feedstock delivery system.
 19. The method according to claim 12, wherein: in the production system, producing the intermediate product from at least a portion of the second cleaned product gas within one or more reactors selected from the group consisting of a multi-tubular reactor, a multi-tubular fixed-bed reactor, an entrained flow reactor, a slurry reactor, a fluid bed reactor, a circulating catalyst reactor, a riser reactor, a can reactor, a microchannel reactor, a fixed bed reactor, a bioreactor and a moving bed reactor.
 20. The method according to claim 19, wherein: the reactor includes one or more bioreactors selected from the group consisting of a continuous stirred tank bioreactor, a bubble column bioreactor, a microbubble reactor, an airlift bioreactor, a fluidized bed bioreactor, a packed bed bioreactor and a photo-bioreactor.
 21. The method according to claim 20, wherein: the bioreactor includes genetically modified organisms which undergo anaerobic respiration. 